Industrial automation components

There are four major components in industrial automation including PLC controllers, HMI
panels, industrial drives and sensors.
The PLC controller is the brain of an industrial automation system; it provides relay control,
motion control, industrial input and output process control, distributed system, and network-
ing control. PLCs often need to work in harsh environmental conditions, withstanding heat,
cold, moisture, vibration and other extreme conditions while providing precise, deterministic
and real-time controls to the other parts of the industrial automation system through reliable
communication links.
The HMI is the graphical user interface for industrial control. It provides a command input
and feedback output interface for controlling the industrial machinery. An HMI is connected
through common communication links to other parts of industrial systems.
Industrial drives are motor controllers used for controlling optimal motor operation. They
are used in a very diverse range of industrial applications and come with a wide range of
voltage and power levels. Industrial drives include but are not limited to AC and DC drives as
well as servo drives that use a motor feedback system to control and adjust the behavior and
performance of servo mechanisms.
Sensors are the hands and legs of the industrial automation system that monitor the
industrial operation conditions, inspections, measurements, and more, in real time. They are
an integral part of industrial automation systems and provide trigger point and feedback for
system control.
Communication is the backbone of all the industrial components for efcient automation
production systems. On the following page is an example picture how all the components
work together through communication links.
Legacy industrial communication protocols
Historically, industrial communications have been developed on serial-based interfaces that
were originally created by different companies and later became standards. The result is
Introduction
In order to remain competitive and thrive,
many businesses are increasingly turning to
advanced industrial automation to maximize
productivity, economies of scale and quality.
The increasingly connected world is inevita-
bly connecting the factory floors. Human ma-
chine interfaces (HMIs), programmable logic
controllers (PLCs), motor control and sen-
sors need to be connected in a scalable and
efficient way. Historically, many industrial
components have been connected through
different serial fieldbus protocols such as
Control Area Network (CAN), Modbus, PRO-
FIBUS

and CC-Link. In recent years, in-

dustrial Ethernet has gained popularity, be-
coming more ubiquitous and offering higher
speed, increased connection distance, and
the ability to connect more nodes. There are
many different industrial Ethernet protocols
driven by various industrial equipment man-
ufacturers. These protocols include Ether-
CAT

, PROFINET

, EtherNet/IP, Sercos

III
and CC-Link

, among others. In this paper,

we will look at many industrial Ethernet pro-
tocols in detail and the increasing need for a
unified hardware and software platform that
enables multiple standards as well as deliv-
ers the real-time, determinism and low laten-
cy required for industrial communications.
An inside look at
industrial Ethernet
communication protocols
Zhihong Lin,
Strategic Marketing Manager
Stephanie Pearson,
Strategic Marketing Manager
Texas Instruments
W H I T E P A P E R
(continued)
An inside look at industrial Ethernet communication protocols November 2013
2 Texas Instruments
many different standards in the market. Because big companies are behind these standards, there is a need
for industrial automation equipment companies to implement many of these protocols within an industrial
system. Due to long life cycle of industrial systems, many serial-based protocols, including PROFIBUS

, CAN
bus, Modbus

and CC-Link

with master slave congurations, are still very popular today.

PROFIBUS is the worlds most successful eldbus technology and is widely deployed in industrial auto-
mation systems including factory and process automation. PROFIBUS provides digital communication for
process data and auxiliary data with speeds up to 12 Mbps and supports up to 126 addresses.
Control Area Network (CAN) bus, a high-integrity serial bus system, was originally created as an automo-
tive vehicle bus and later came to be used as one of the eldbuses for industrial automation. It provides a
physical and data link layer for serial communication with speeds up to 1 Mbps. CANopen

and DeviceNet
are higher level protocols standardized on top of CAN bus to allow interoperability with devices on the same
industrial network. CANopen supports 127 nodes on the network while DeviceNet supports 64 nodes on the
same network.
Modbus is a simple, robust and openly published, royalty free serial bus that connects up to 247 nodes in the
link. Modbus is easy to implement and run on RS-232 or RS-485 physical links with speeds up to 115K baud.
CC-Link was originally developed by Mitsubishi and is a popular open-architecture, industrial network
protocol in Japan and Asia. CC-Link is based on RS-485 and can connect with up to 64 nodes on the same
network with speeds up to 10 Mbps.
Ethernet is becoming ubiquitous and cost effective, with common physical links and increased speed. As
such, many industrial communication protocols are moving to Ethernet-based solutions. Ethernet commu-
nications with TCP/IP typically are non-deterministic, and reaction time is often around 100 ms. Industrial
Figure 1: Industrial automation components and communication links
Industrial Ethernet
communication
protocols
An inside look at industrial Ethernet communication protocols November 2013
3 Texas Instruments
Ethernet protocols use a modied Media Access Control (MAC) layer to achieve very low latency and deter-
ministic responses. Ethernet also enables a exible network topology and a exible number of nodes in the
system. Lets look at some of the popular Industrial Ethernet protocols in detail.
EtherCAT was originally developed by Beckhoff to enable on-the-y packet processing and deliver real-time
Ethernet to automation applications and that can provide scalable connectivity for entire automation systems,
from large PLCs all the way down to the I/O and sensor level.
EtherCAT, a protocol optimized for process data, uses standard IEEE 802.3 Ethernet Frames. Each slave
node processes its datagram and inserts the new data into the frame while each frame is passing through.
The process is handled in hardware so each node introduces minimum processing latency, enabling the fast-
est possible response time. EtherCAT is the MAC layer protocol and is transparent to any higher level Ethernet
protocols such as TCP/IP, UDP, Web server, etc. EtherCAT can connect up to 65,535 nodes in a system, and
EtherCAT master can be a standard Ethernet controller, thus simplifying the network conguration. Due to
the low latency of each slave node, EtherCAT delivers exible, low-cost and network-compatible industrial
Ethernet solutions.
EtherNet/IP is an industrial Ethernet protocol originally developed by Rockwell. Unlike EtherCAT, which is
MAC-layer protocol, EtherNet/IP is application-layer protocol on top of TCP/IP. EtherNet/IP uses standard
Ethernet physical, data link, network and transport layers, while using Common Industrial Protocol (CIP) over
TCP/IP. CIP provides a common set of messages and services for industrial automation control systems,
and it can be used in multiple physical media. For example, CIP over CAN bus is called DeviceNet, CIP over
dedicated network is called ControlNet and CIP over Ethernet is called EtherNet/IP. EtherNet/IP establishes
communication from one application node to another through CIP connections over a TCP connection, and
multiple CIP connections can be established over one TCP connection.
EtherNet/IP uses the standard Ethernet and switches, thus it can have an unlimited number of nodes in a
system. This enables one network across many different end points in a factory oor. EtherNet/IP offers com-
plete producer-consumer service and enables very efcient slave peer-to-peer communications. EtherNet/IP
is compatible with many standard Internet and Ethernet protocols but has limited real-time and deterministic
capabilities.
PROFINET is widely used industrial Ethernet by major industrial equipment manufactuerers such as Siemens
and GE. It has three different classes. PROFINET Class A provides access to a PROFIBUS network through
proxy, bridging Ethernet and PROFIBUS with a remote procedure calling on TCP/IP. Its cycle time is around
100ms, and it is mostly used for parameter data and cyclic I/O. The typical application includes infrastructure
and building automation. PROFINET Class B, also referred as PROFINET Real-Time (PROFINET RT), introduces
a software-based real-time approach and has reduced the cycle time to around 10ms. Class B is typically
An inside look at industrial Ethernet communication protocols November 2013
4 Texas Instruments
used in factory automation and process automation. PROFINET Class C (PROFINET IRT), is Isochronous and
Real-Time, requiring special hardware to reduce the cycle time to less than 1ms to deliver the sufcient
performance on the real-time industrial Ethernet for motion control operations.
PROFINET RT can be used in PLC-type applications, while PROFINET IRT is a good t for motion applica-
tions. Branch and Star are the common topology used for PROFINET. Careful topology planning is required for
PROFINET networks to achieve the required performance of the system.
POWERLINK was originally developed by B&R. Ethernet POWERLINK is implemented on top of IEEE 802.3
and, therefore, allows a free selection of network topology, cross connect and hot plug. It uses a polling and
time slicing mechanism for real-time data exchange. A POWERLINK master or Managed Node controls the
time synchronization through packet jitter in the range of 10s of nanoseconds. Such a system is suitable for
all kinds of automation systems ranging from PLC-to-PLC communication and visualization down to motion
and I/O control. Barriers to implement POWERLINK are quite low due to the availability of open-source stack
software. In addition, CANopen is part of the standard which allows for easy system upgrades from previous
eldbus protocols.
Sercos III is the third generation of Serial Real-time Communication System (Sercos). It combines on-the-
y packet processing for delivering real-time Ethernet and standard TCP/IP communication to deliver low
latency industrial Ethernet.
Much like EtherCAT, a Sercos III slave processes the packet by extracting and inserting data to the Ether-
net frame on-the-y to achieve low latency. Sercos III separates input and output data into two frames. With
cycle times from 31.25 microseconds, it is as fast as EtherCAT and PROFINET IRT. Sercos III supports ring or
line topology. One key advantage to using ring topology is communication redundancy. Even if the ring breaks
due to failure of one slave, all remaining slaves still get the Sercos III frames with input/output data. Sercos III
can have 511 slave nodes in one network and is most used in servo drive controls.
CC-Link IE is the industrial Ethernet technology of CC-Link, which was originally developed by Mitsubishi.
CC-Link IE has two versions: CC-Link IE Control and CC-Link IE Field. CC-Link IE control is intended for
controller-to-controller communications and can have 120 nodes per network. CC-Link IE eld is intended
for I/O communications and motion control, and it can have 254 nodes per network. CC-Link IE leverages the
Ethernet data link layer, and its control frames are directly embedded in the Ethernet frame. Only ring topol-
ogy is supported in CC-Link without switches. This can provide network redundancy, but a limited number of
nodes can be supported in a network, and the cycle time is dependent on the number of the nodes in
the network.
SPRY254 2013 Texas Instruments Incorporated
Important Notice: The products and services of Texas Instruments Incorporated and its subsidiaries described herein are sold subject to TIs standard terms and
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Modbus /TCP, an extension of Modbus, was originally developed by Schneider Electric and uses Modbus
messaging over TCP/IP on top of Ethernet. Modbus/TCP is simple to implement on the standard Ethernet
network, but it does not guarantee real-time and deterministic communications.
To enable industrial equipment manufacturers with an economic and exible means to implement a variety of
industrial communication protocols, Texas Instruments has integrated a low-latency, low-power and program-
mable Industrial Communication SubSystem (ICSS) into many of its system on chips. The ICSS provides a
more cost-effective, exible and future-proof solution for industrial communications as compared to FPGAs,
ASICs and other alternative solutions. By integrating the ICSS into a single chip, TIs exible hardware
platform empowers manufacturers to implement more cost-effective, deterministic, efcient and software-
programmable industrial automation systems.
We are at the dawn of the third industrial revolution in which industrial automation will again drive the
economy. The success of industrial automation depends on a reliable and efcient communication network
that connects all the components of the factory to work together effectively. The popularity and ubiquity
of Ethernet will continue to motivate the legacy factory to upgrade to industrial Ethernet. Many different
industrial Ethernet protocols have been implemented in the eld, each with its own pros and cons. Future
industrial Ethernet protocols will continue to evolve and converge to deliver hard real-time, deterministic com-
munication links with better reliability and integrated safety. Ethernet also requires a common, programmable
hardware platform, such as Texas Instruments Sitara AM335x ARM

processor with integrated ICSS to

enable a low-cost, exible system capable of supporting multiple protocols and forward-looking implementa-
tion for new protocols to power the industrial communication engine of the industrial automation.
For more information on the Sitara AM335x product line, please visit www.ti.com/lsds/ti/arm/
sitara_arm_cortex_a_processor/products.page. Also, to preview the new AM4x and AM5x Sitara proces-
sors families, which will offer even more performance for your industrial needs, please visit
www.ti.com/am4x-sps and www.ti.com/am5x-sps.
The authors would like to thank Srik Gurrapu, Thomas Leyrer, Frank Walzer, and Thomas Mauer, Stacie
Ocnaschek, Jessica Callaway and Avner Goren for their contributions to this paper.
5 Texas Instruments
Future trend
Industrial
communication enabler
from Texas Instruments
Acknowledgement
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